Precast thermally separated cantilevered balcony system and method of using same

ABSTRACT

A precast thermally separated cantilevered balcony system includes a concrete slab, a thermal separation component and a plurality of reinforcing bars. The concrete slab has an inside edge and a plurality of reinforcing bars extending therethrough generally orthogonal to the inside edge. The thermal separation component is an elongate member extending along the inside edge of the concrete slab. The plurality of reinforcing bars extend through the thermal separation component and extend inwardly from the thermal separation component. A method of constructing a building having at least one precast thermally separated cantilevered balcony system is discussed.

FIELD OF THE DISCLOSURE

This disclosure relates to a precast cantilevered balcony system and in particular a precast thermally separated cantilevered balcony system.

BACKGROUND

Balconies are a very common feature in multi-unit buildings. The heat transfer between a balcony and the main structure may significantly affect the energy efficiency of a building. While this issue has always been important with the heightened focus on “green” building the heat transfer between a balcony and the main structure has gained importance.

Accordingly it is desirable to provide a thermal separation between a balcony and the main structure when incorporating a floor joist system for the floor.

Some products have been suggested which address thermal separation that require formwork and special devices for coordinating with a floor joist system. For example the Halfen Hit™ shown and described in U.S. Pat. No. 8,733,052 issued to Froehlich on May 27, 2014 described a thermally insulating construction component. While this product does provide a thermal barrier, it is expensive to use. In addition, it is time consuming to use on site during construction. As is well known in the construction industry time is money.

While providing a thermal break between a balcony and the main structure is more straightforward when the balcony is fully supported by structural members, when the balcony is a cantilevered balcony the typical construction method is both time consuming and expensive.

Accordingly it would be desirable to provide a method of construction that is both cost effective and relatively easy to use. Further it would be desirable to provide a product that would be cost effective and relatively easy to install for cantilevered balcony construction.

SUMMARY

The present disclosure relates to a precast thermally separated cantilevered balcony system having a concrete slab, a thermal separation component and a plurality of reinforcing bars. The concrete slab has an inside edge and a plurality of reinforcing bars extending therethrough generally orthogonal to the inside edge. The thermal separation component is an elongate member extending along the inside edge of the concrete slab. The plurality of reinforcing bars extend through the thermal separation component and extend inwardly from the thermal separation component.

The cantilevered balcony may be designed to be positioned on an external wall of a building.

The thermal separation component may be positioned in the middle of the wall. Alternatively, the thermal separation component may be positioned at the outside of the wall. Alternatively, the thermal separation component may be positioned at the inside of the wall.

The thermal separation component may have a cross section which is generally rectangular.

Alternatively, the thermal separation component may have a cross section which is generally L-shaped and has a bottom portion with a bottom face generally in alignment with a bottom face of the concrete slab.

Alternatively, the thermal separation component may have a cross section which is generally J-shaped and has a bottom portion with a bottom face generally in alignment with a bottom face of the concrete slab and top portion generally on a top face of the concrete slab.

Alternatively, the thermal separation component has a cross section which is generally I-shaped and has a bottom portion with a bottom face generally in alignment with a bottom face of the concrete slab and top portion generally on a top face of the concrete slab.

The concrete slab may have a step along the inside edge.

The thermal separation component may have an inside face and the reinforcing bars are arranged in a plurality of upper reinforcing bars and lower reinforcing bars and may further include a joist bearing seat attached to inside face of the thermal separation component and the plurality of lower reinforcing bars extend therethrough and the plurality of upper reinforcing bars extend over the joist bearing seat.

The joist bearing seat may be designed to receive a joist.

The joist may be an open webbed steel joist.

The plurality of upper reinforcing bars and the plurality of lower reinforcing bars may be designed to be embedded in a thickened floor slab.

The plurality of upper reinforcing bars may be designed to be embedded in a thin floor slab.

The plurality of reinforcing bars may be designed to be embedded in a structural floor slab.

The present disclosure also relates to a method of constructing a building having at least one cantilevered balcony comprising the steps of:

-   constructing at least one exterior wall -   attaching a precast thermally separated cantilevered balcony system     including: -   a concrete slab having an inside edge and a plurality of reinforcing     bars extending therethrough generally orthogonal to the inside edge; -   a thermal separation component being an elongate member extending     along the inside edge of the concrete slab; and -   wherein the plurality of reinforcing bars extend through the thermal     separation component and extend inwardly from the thermal separation     component; and -   a floor slab having the plurality of reinforcing bars embedded     therein.

The precast thermally separated cantilevered balcony system may further include a joist seat and further including a joist attached thereto.

The floor slab may be a thickened floor slab.

The floor slab may be a thin floor slab.

Further features will be described or will become apparent in the course of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments will now be described by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a precast thermally separated cantilevered balcony system;

FIG. 2 is a cross sectional view of an embodiment of a precast thermally separated cantilevered balcony system showing a thermal separation component at the middle of the wall and steel reinforcing bars;

FIG. 3 is a side view of an embodiment of a precast thermally separated cantilevered balcony system showing a thermal separation component at the outside of the wall, the rebar is removed for clarity;

FIG. 4 is a side view of an embodiment of a precast thermally separated cantilevered balcony system showing a thermal separation component at the inside of the wall, the rebar is removed for clarity;

FIG. 5 is a side view of an embodiment of a precast thermally separated cantilevered balcony system showing a thermal separation component that is at the middle of the wall, the rebar is not shown for clarity;

FIG. 6 is a side view of an embodiment of a precast thermally separated cantilevered balcony system showing a thermal separation component that is generally J-shaped cast into the balcony to provide separation down the middle and the bottom of the balcony with thermal separator material placed above the balcony and below the wall above, the rebar is not shown for clarity;

FIG. 7 is a side view of an embodiment of a precast thermally separated cantilevered balcony system showing a thermal separation component that is generally I-shaped, the thermal separator cast in the middle of the wall with a thermal separator material placed above the balcony and below the balcony, the rebar is not shown for clarity;

FIG. 8 is a side view of an embodiment of a precast thermally separated cantilevered balcony system having a joist bearing seat and shown with a joist and a thickened floor slab;

FIG. 9 is a side view of an embodiment of a precast thermally separated cantilevered balcony system having a joist bearing seat and shown with a joist and a thin floor slab. When there is a thin slab the precast reinforcing bars will not extend into the floor slab and the balcony will be supported by posts on the outside face;

FIG. 10 is a top view of a precast thermally separated cantilevered balcony system in a building and showing the connection of the dowel portions of the balcony reinforcing bars and the floor structure reinforcing bars; and

FIG. 11 is a side view of two precast thermally separated cantilevered balcony system installed one above the other on temporary support posts installed at the outer end of the balconies.

DETAILED DESCRIPTION

Referring to FIG. 1, the precast thermally separated cantilevered balcony system is shown generally at 10. The thermally separated cantilevered balcony system 10 includes a concrete reinforced cantilevered slab 12, a thermal separation component 14 and a plurality of reinforcing bars 16 extending outwardly from the thermal separation component 14.

Preferably the thermal separation component 14 is made from a non-porous rigid insulating material that has a high compressive strength and that can withstand structural forces.

The cantilevered concrete slab has a top face 18, a bottom face 20, an inside edge 22 and an outside edge 24. The plurality of reinforcing bars 16 are embedded in the concrete slab, extend through the thermal separation component 14. The reinforcing bars 16 may be a plurality of upper reinforcing bars 26 and lower reinforcing bars 28. The portion of the reinforcing bars 16 that extend past the inside face 22 of the precast slab 12 are typically referred to as dowels. The dowels allow for splicing of the balcony slab 12 into the reinforcing bars 31 of the floor slab 30. This can best be seen in FIG. 10. Alternatively, the reinforcing bars 16 may be terminated at the inside face 22 if the outside of the balcony unit is simply supported with posts 78 as shown in FIG. 9.

When the precast thermally separated cantilevered balcony system 10 is in situ in a building the reinforcing bar or dowels 16 are spliced into the floor slab reinforcing bars 31 of the floor slab 30.

The concrete slab 12 includes a step 32 along the inside edge. The step 32 is a step up such that a person on the balcony would step up to be on the level of the floor inside. The step 32 serves to provide at least some passive rain screen moisture protection. In addition, the top surface 18 of concrete slab 12 has a 1.5% slope so that it will shed water. Alternatively a step may be created between the precast balcony slab 12 of the precast thermally separated cantilevered balcony system 10 and a floor slab 30 as shown in FIG. 3.

The precast thermally separated cantilevered balcony system 10 is designed to be positioned on a structural wall 34. The concrete slab 12 of the precast thermally separated cantilevered balcony system 10 extends outwardly from one side of the wall 34 and the reinforcing bars 16 extend inwardly from the other side of the wall 34 in the embodiments shown in FIGS. 1 to 8. An upper wall 36 extends upwardly from the precast thermally separated cantilevered balcony system 10.

It will be appreciated by those skilled in the art that the location of the thermal separation component may vary as shown in FIGS. 2 to 4. For example as shown in FIG. 2 the thermal separation component 14 is positioned in the middle of the wall. Alternatively as shown in FIG. 3 the thermal separation component 14 is positioned at the outside of the wall. In another alternative shown in FIG. 4 the thermal separation component 14 is positioned at the inside of the wall.

The thermal separation component 14 extends along the inside edge 22 of the concrete slab 18 from one side thereof to the other. As shown in FIGS. 2 to 7 the thermal separation component 14 may have different cross sectional shapes. For example the thermal separation component 14 has a cross section which is generally rectangular as shown in FIGS. 2 to 4. Alternatively the thermal separation component 14 shown in FIG. 5 as 38 has a cross section which is generally L-shaped with a bottom portion 40 and an upper portion 42 extending generally upwardly orthogonally thereto. The bottom portion 40 has a bottom face 44 which is generally in alignment with a bottom face 20 of the concrete slab 12. In another embodiment the thermal separation component 14 shown in FIG. 6 as 50 has a cross section which is generally J-shaped with a bottom portion 52, an upright portion 54 and a top portion 56 that is set as part of the upper wall assembly 36. The upright portion 54 extends generally orthogonally to the bottom portion 52 and the top portion 56 which extends generally orthogonally to the upright portion on both sides thereof. The bottom portion 52 of thermal separation component 50 has a bottom face 58 which is generally in alignment with a bottom face 20 of the concrete slab 12. The top portion 56 is generally on the top face 33 of the concrete step 32. The J-shaped thermal separation component 50 is cast into the balcony to provide separation down the middle and the bottom of the balcony with thermal separator material placed above the balcony and below the wall above. In another embodiment the thermal separation component 14 and is shown generally at 60 in FIG. 7 has a cross section which is generally I-shaped with a bottom portion 62, and upright portion 64 and a top portion 66. The bottom portion 62 of thermal separation component 60 is generally placed under the bottom face 20 of the concrete slab 12 as part of the lower wall assembly 34. The top portion 66 is generally on the top face 33 of the concrete step 32. The I-shaped thermal separator component 60 is cast in the middle of the wall with thermal separator material placed above the balcony and below the balcony.

Referring to FIGS. 1, 8 and 9 the precast thermally separated cantilevered balcony system 10 may include a joist bearing seat. The joist bearing seat is operably attached to the inside face of the thermal separation component 14. The lower reinforcing bars extend from the concrete slab 12 through the thermal separation component 14 and through the joist bearing seat 70. As shown herein the joist bearing seat 70 may be used with an open webbed steel joist but other types of joists may also be used.

The joist bearing seat 70 is designed to receive a joist 72 to be positioned thereon as shown in FIGS. 8 and 9. As shown in FIG. 8 a thickened floor slab 74 may be used with the joist 72. Alternatively as shown in FIG. 9, a thin floor slab 76 may be used when the outside of the balcony is supported with posts and the balcony is simply supported, the reinforcing of the balcony is independent of the floor slab 76.

It will be appreciated by those skilled in the art that the precast thermally separated cantilevered balcony system described herein provides a number of advantages. For example with the precast thermally separated cantilevered balcony system 10, a framing company can continue installation without the need to install formwork for the cantilevered balconies. Further when combining this new system 10 with a composite joist stay-in-place formwork system it provides a complete solution wherein no formwork is required. The built in joist bear seat 70 replaces the need to provide special support details. Less detailing, less shop and less field hours, serve to provide a cost savings. Accordingly the use of the precast thermally separated cantilevered balcony system 10 may help to reduce or even eliminate the formwork trade from the job which will help to reduce construction costs and make project scheduling easier.

In use the preformed thermally separated cantilevered balcony is particularly useful in multi-story building construction. Use of the precast thermally separated cantilevered balcony system can help to reduce on-site construction costs. The precast thermally separated cantilevered balcony system can be built off site to the desired specification and then brought to the building site ready to install.

A method of constructing a building having at least one cantilevered balcony unit includes the following steps. The walls of a framed building are erected and the floor system and deck is installed. The walls of the framed building include at least one exterior wall 34. The precast thermally separated cantilevered balcony system 10 is set and supported on the inside on wall 34 and supported on the outside with temporary support posts 90 as shown in FIG. 11. Attaching a floor slab 30 having the plurality of reinforcing bar 31 embedded therein, slice floor reinforcing bars 16 of the installed precast system 10 to the reinforcing bars 31 of the floor slab 30.

Generally speaking, the systems described herein are directed to cantilevered balconies. The description and drawings are illustrative of the disclosure and are not to be construed as limiting the disclosure. Numerous specific details are described to provide a thorough understanding of various embodiments of the present disclosure. However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present disclosure.

As used herein, the terms, “comprises” and “comprising” are to be construed as being inclusive and open ended, and not exclusive. Specifically, when used in the specification and claims, the terms, “comprises” and “comprising” and variations thereof mean the specified features, steps or components are included. These terms are not to be interpreted to exclude the presence of other features, steps or components.

As used herein the “operably connected” or “operably attached” means that the two elements are connected or attached either directly or indirectly. Accordingly the items need not be directly connected or attached but may have other items connected or attached therebetween. 

What is claimed is:
 1. A precast thermally separated cantilevered balcony system comprising: a concrete slab having an inside edge and a plurality of reinforcing bars extending therethrough generally orthogonal to the inside edge; a thermal separation component being an elongate member extending along the inside edge of the concrete slab; and wherein the plurality of reinforcing bars extend through the thermal separation component and extend inwardly from the thermal separation component.
 2. The precast thermally separated cantilevered balcony system of claim 1 wherein the cantilevered balcony is designed to be positioned on an external wall of a building.
 3. The precast thermally separated cantilevered balcony system of claim 2 wherein the thermal separation component is positioned in the middle of the wall.
 4. The precast thermally separated cantilevered balcony system of claim 2 wherein the thermal separation component is positioned at the outside of the wall.
 5. The precast thermally separated cantilevered balcony system of claim 2 wherein the thermal separation component is positioned at the inside of the wall.
 6. The precast thermally separated cantilevered balcony system of claim 1 wherein the thermal separation component has a cross section which is generally rectangular.
 7. The precast thermally separated cantilevered balcony system of claim 1 wherein the thermal separation component has a cross section which is generally L-shaped and having a bottom portion with a bottom face generally in alignment with a bottom face of the concrete slab.
 8. The precast thermally separated cantilevered balcony system of claim 1 wherein the thermal separation component has a cross section which is generally J-shaped and having a bottom portion with a bottom face generally in alignment with a bottom face of the concrete slab and top portion generally on a top face of the concrete slab.
 9. The precast thermally separated cantilevered balcony system of claim 1 wherein the thermal separation component has a cross section which is generally I-shaped and having a bottom portion with a bottom face generally in alignment with a bottom face of the concrete slab and top portion generally on a top face of the concrete slab.
 10. The precast thermally separated cantilevered balcony system of claim 1 wherein the concrete slab has a step along the inside edge.
 11. The precast thermally separated cantilevered balcony system of claim 1 wherein the thermal separation component has an inside face and the reinforcing bars are arranged in a plurality of upper reinforcing bars and lower reinforcing bars and further including a joist bearing seat attached to inside face of the thermal separation component and the plurality of lower reinforcing bars extend therethrough and the plurality of upper reinforcing bars extend over the joist bearing seat.
 12. The precast thermally separated cantilevered balcony system of claim 11 wherein the joist bearing seat is designed to receive a joist.
 13. The precast thermally separated cantilevered balcony system of claim 12 wherein the joist is an open webbed steel joist.
 14. The precast thermally separated cantilevered balcony system of claim 12 wherein the plurality of upper reinforcing bars and the plurality of lower reinforcing bars are designed to be embedded in a thickened floor slab.
 15. The precast thermally separated cantilevered balcony system of claim 12 wherein the plurality of upper reinforcing bars are designed to be embedded in a thin floor slab.
 16. The precast thermally separated cantilevered balcony system of claim 1 wherein the plurality of reinforcing bars are designed to be embedded in a structural floor slab.
 17. A method of constructing a building having at least one cantilevered balcony comprising the steps of: constructing at least one exterior wall attaching a precast thermally separated cantilevered balcony system including: a concrete slab having an inside edge and a plurality of reinforcing bars extending therethrough generally orthogonal to the inside edge; a thermal separation component being an elongate member extending along the inside edge of the concrete slab; and wherein the plurality of reinforcing bars extend through the thermal separation component and extend inwardly from the thermal separation component; and a floor slab having the plurality of reinforcing bars embedded therein.
 18. The method of constructing a building of claim 17 wherein the precast thermally separated cantilevered balcony system further includes a joist seat and further including a joist attached thereto.
 19. The method of constructing a building of claim 18 wherein the floor slab is a thickened floor slab.
 20. The method of constructing a building of claim 18 wherein the floor slab is a thin floor slab.
 21. The method of constructing a building of clmikeaim 17 further including the steps of attaching a plurality of precast thermally separated cantilevered balcony systems. 